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SHOP TTNANI,]AI,
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BULLDOZER D155A-6
o
O
Machine model
Serial number
D155A-6
85001 and up
40 Troubleshooting Failure code table and fuse locations
o D1554-6
xorrl'lsu
rO Troubleshooting
Failure codes table Component Category of
Action code
Failure code
E03
150010
Transmission clutch: Abnormal
Ptl
E03
tSsALl
Forward clutch: Fill high
PN
E03
lsSALH
Forward clutch: Fill Low
E03
l5SBLi
Reverse clutch: Fill high
Pt7
E03
I55BLH
Reverse clutch: Fill Low
PTT
2
Trouble (Displayed on screen)
,
In cnarge
PN
history Electrical system Electrical system Electrical system Electrical system Electrical
system
Electical
E03
l5SELl
Speed 1st clutch: Fill high
Prf
E03
15SELH
Speed 1st clutch: Fill Low
PN
E03
l55FLl
Speed 2nd clutch: Fill high
Prf
E03
155FLH
SDeed 2nd clutch: Fill Low
P/T
E03
tsscLl
Speed 3rd clutch: Fill high
PII
E03
1sSGLH
Speed 3rd clutch: Fill Low
P/T
E04
2201L1
Rioht clutch: See the list
t'l
I
Electical sy$em
E04
220r LH
Right clutch: See the list
Plr
Electrical system
E04
22D2L1
Left clutch: See the list
Pfi
Electic€l
E04
2?O2LH
Left clutch: See the list
Pfi
2300KM
$all in lst gear speed
P/T
E04
230tLt
Right brake: Fill high
Plr
E04
230tLH
Righl brake: Fill low
Pfi
Eleckical system
E04
2302L1
Lefl brake: Fill high
PN
E04
23021H
Left brake: Fill low
PN
TRFAKA
ECM HOLD RELAY Disconnection
Pn
AAlONX
Air Cleaner Clogging
MON
ABOOMA
Battery Charge Abnormal
MON
Electrical sysrem Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical
B@BAzG Eng Oil Press Low
ENG
B@BCNS Eng Water Overheat
ENG
wBczK
MON
Eng Water Level Low
B@EENS
T/C Oil Overheat
Pn
B@HANS
Hyd Oil Overheat
MON
E04
cA1fi
EMC Cdtical lnternal Failure
ENG
E0/t
cA
Eng Ne and Bkup Speed Sens Error
ENG
s
Reference manual
system Electrical system
Eleckical system Elec{rical system Electrical system Electrical system
sysrem Electrical system Electrical system Electrical system
Troubleshooting by failure code, Part 1
sEN03206-00
sy$em Mechanical system Mechanical system Electrical system
Elecfical sysrem
D1554-6
Action cooe
Failure code
Trouble (Displayed on screen)
E03
c,{122
Chg (boost) Air Press Sensor High Error
o
ENG
E03
cA123
Chg (boost) Air Press Sensor Low Error
ENG
E03
cA131
Throttle Sensor High Enor
ENG
E03
c4132
Throttle Sensor Low Error
ENG
E02
c4135
Eng Oil Press Sensor High Effor
ENG
E02
cAr41
Eno Oil Press Sensor Low Error
ENG
E02
c4144
Coolant Temp Sens High Error
ENG
cA145
Coolant Temp Sens Low Error
ENG
E01
cAt53
Chg (boost) Air Temp Sensor High Error
ENG
E0r
c4154
Chg (boost) Air Temp Sensor Low Error
ENG
E03
c4187
Sens Supply 2 Volt Low Enor
ENG
E03
c4221
Ambient Press Sens High Error
ENG
E03
cA222
Ambient Press Sens Low Error
ENG
E03
cA227
Sens Supply 2 Volt High Error
ENG
cA234
Eng Overspeed
ENG
E03
cA238
Ne Speed Sens Supply Volt Error
ENG
E01
cA263
FuelTemp Sensor High Enor
ENG
E02
o
Component in charge
E01
cA265
Fuel Temo Sensor Low Error
ENG
E03
cA271
PCV'I Short Error
ENG
E03
c4272
PCV1 Open Error
ENG
E03
c4273
PCV2 Short Error
ENG
E03
cac74
PCV2 Open Error
ENG
E03
cA3?2
lnj #1 Oper/Short Error
ENG
E03
c4323
Inj #5 Open/Short Error
ENG
E03
c4324
Inj #3 Open/Short Error
ENG
E03
cA325
lni #6 Ooen/Short Enor
ENG
E03
cA331
Ini #2 ODen/Short Erfor
ENG
E03
cA332
Inj #4 Open/Short Error
ENG
E04
cA342
Calibration Code lncomoatibilitv
ENG
E03
c4351
lnieclors Drive Circuil Error
ENG
E03
c4352
Sens Supply 1 Volt Low Error
ENG
0155A6
Category of
history
Reference manual
Eleclrical sYStem
Electrical system Electric€l system system Electrical system Electrical syste m
syslem Electrical system Electric€l system Electrical system Electrical sysrem Electrical system Electrical system Electric€l system Electrical system Electrical system
Troubleshooting bv failure
Part
1
code.
sEN03206-00
I
i
I |
Elecfical sYstem
Electrical system Electrical syste m
Electrical system Electric€l sysrem Electrical sYStem
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical sysrem Electrical system Electrical system Electric€
Troubleshootino by failure code,
Patt2
sEN03207-00
sYstem
3
40 Troubleshooting
Component In charge
Action code
Failure code
E03
cA386
Sens Supply 1 Volt High Error
ENG
E04
c4441
Battery Voltage Low Effor
ENG
E04
cA4/,2
Battery Voltage High Error
ENG
E03
c4449
Rail Press Very High Error
ENG
E03
cAit51
Rail Press Sensor High Enor
ENG
E03
cAils2
Rail Press Sensor Low Enor
ENG
E02
cA553
Rail Press High Error
ENG
Trouble (Displayed on screen)
E03
cA554
Rail Press Sensor In Range Eror
ENG
E02
cA559
Rail Press Low Error
ENG
E03
c4689
Eng Ne Speed Sensor Enor
E03
cA73t
Eng Bkup Speed Sens Phase Error
ENG
E04
c4757
All Continuous Data Lost Error
ENG
E03
c4778
Eng Bkup Speed Sensor Error
ENG
E03
cAt 633
KOMNET Datalink Timeout Error
ENG
E03
cA2t85
Throt Sens Sup Volt High Enor
ENG
E03
c42186
Throt Sens Sup Volt Low Enor
E03
cA2249
Rail Press Very Low Enor
E01
cA2555
Grid Htr Relay Volt Low Enor
ENG
E01
cAz,fi
Grid Htr Relay Volt High Error
ENG
DII OKA
Battery relay: Disconnection
PN
D1'OKB
Battery Relay: Drive Shorl Circuit
Pn
EO2
Dl30KA
Neutral relav: Disconnection
PN
E02
o130KB
Neutral relay: Short circuit
Pfi
E01
D161KA
Back-up alarm relay: Disconnection
PN
E01
DI6' KB
Back-up alarm relay: Short circuit
P/T
Dl90KA
ACC signal relay: Disconnection
DI90KB
ACC signal relay: Short circult
PN
E03
D5ZKKX
Throttle Dial: Out of normal ranoe
PTT
E03
DAFRKR
CAN Disconnection (Monitor)
MON
E03
DB2RKR
CAN Disconnection (Engine controller)
ENG
E03
4
DB9OKR
PT controller: Can mmmunication lost
Plr
Category of history
Reference manual
Electrical sysrem Electrical system Electrical system Electrical sysrem Eleclric€l system Electrical system Electrical
system Eleclrical system
Electical system Electdcal system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Troubleshootinq by tailure code, Part 2 DtrNUJIU/ -UU
Electical system Electrical system Electrical system Electric€l system
Elecfical system Electrical system Electrical syslem Electrical system Electrical system Electrical sy6tem Electrical
system
Troubleshooting by failure code, Part 3
sEN03208-01
Electrical system
Dl55AS
40 Troubleshooting
sEN03204-02
Action code
Failure
E03
DBEOKK
PT controller: Source volhoe reduction
Plr
E0t
DBEOKT
PT controller: Abnormality in controller
Plr
E02
DBE6KK
PT controller: Source voltage r€duction
P/T
E02
DBETKK
PT controller: Source voltaoe reduction
PN
E04
DBE9KQ
PT controller: Type select signal
PN
EO2
DDI2KA
Shift uo Sw: Dismnnection
P/T
E02
DDI2KB
Shift up Sw: Short circuit
P/T
E02
DDI3KA
Shift down Sw: Disconnection
Prf
E02
DD13KB
Shifr down Sw: Short circuit
PN
E03
DDI4KA
Parking lever Sw: Disconnection
PN
E03
DD14KB
Parkino lever Sw: Short circuit
PN
E02
DDDDKA
Back up brake Sw: Disconnection
Prf
EOz
DDDDKB
Back uo brake Sw: Short circuit
Prf
E02
DDDDKX
Back up brake Sw: Signal mismatch
Prf
Trouble (Displayed on screen)
code
E01
DGTl KA
E0t
DGT1
Component In
charge
T/C oil lemo sensor: Abnormal
P/T
T/C oil temo sensor abnormal
Pft
DH2lKA
Weq pressure sensor: Disconnection
PTT
DH2.IKB
Weq oressure sensor: Short circuit
PN
E03
DKIOKX
Fuel control Dial: Out of normal
E03
DK3OKA
ST lever 'l: Disconnection
E03
DK3OKB
ST lever
E04
DK3OKX
ST lever 1: Oul of normal range
Pfi
E04
DK30KZ
ST lever: Disconnection or short circuit
Pfi
E03
DK3OL8
ST lever: Signal mismatch
Prf
E03
DK3lKA
ST lever 2: Disconnection
Prf
E03
DK3I KB
ST lever 2: Short circuit
Prf
E03
DK4(IKA
Brake potentiometer: Disconnection
Prf
E03
DK4{IKB
Brake potentiometer: Short circuit
PN
E04
KX
DK55KX
'1:
range
Short circuit
FR lever: Out of normal range
P/T
Ptl PN
P/T
E04
oK55KZ
FR lever: Disconnection or short circuit
P/T
E03
DK55L8
FR lever: Sional mismatch
P/T
D155A-6
Category of history Electric€l sysrem Electrical system Electrical system Electrical system Electrical system Electric€l system Electrical system Electrical system Electrical system E lectrical system Electrical system Electrical system Electrical system Elecuical
Reference manual
sy$em Electrical system Elec{rical
sy$em Elecfic€l system Elechical system Electfical system Electric€l system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electric€
Ifi"?llT#[91
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sysrem Electrical syste m
Electrical syste m
Electrical syste m
Electrical syEtem
5
40 Troubleshooting
sEN03204-02
Action
Failure
oode
cooe
E03
DK56KA
Trouble (Displayed on screen) FR lever'l : Disconnection
Component in charge
Category ol
history
Referenoe manual
Pfr
Electrical
Trou bleshooting
syslem
E03
DK56KB
FR lever 'l: Short circuit
Pfi
Electrical
E03
DK57KA
FR lever 2: Disconnection
Ptl
E03
DK57KB
FR lever 2: Short circuit
PIT
Electrical sysrem Electrical
syslem
sy$em
DKHI KA
Pitch angle senson Disconneclion
Ptf
E03
DKHIKB
Pitch angle sensor Short cirorit
PIT
E0t
DLT3KA
T/M out-speed sensor: Discon neclion
Pfi
E01
DLT3KB
T/M oufspeed sensor: Abnormal
Pfi
E0t
DWTBKA
Fan rev EPC: Disconnection
Ptl
E0l
DWTBKB
Fan rev EPC: Short circuit
Pfi
Electrical
E04
DWN3KA
Ssp solenoid: Disconneclion
Ptt
E0,0
DWN3KB
Ssp solenoid: Short circuit
PIT
Electrical sYstem Electrical
DWN3KY
Ssp solenoid: Short circuit
Ptf
E01
DWN5KA
Fan pump solenoid: Disconnection
Ptt
E01
DWNsKA
Fan pump solenoid: Short circuit
w/E
E03
OXH4KA
1st dutch ECMV: Dis@nneclion
PN
E03
DXH4KB
lst dutch ECMV: Short circuit
system Eleckical system syslem
syslem Electrical sysIem Electrical system Electrical sysrem Electrical Trou bleshootinq
Ptf
by failure code,
Electrical sysrem Electrical sysrem Electrical system Eleclrical sysrem Electrical
'lst clutch ECMV: Short circuit
Ptf
E03
DXHsKA
2nd dutch ECMV: Disoon nection
PIT
E03
DXHSKB
2nd dutch ECMV: Short circuit
Ptf
E03
DXHsKY
2nd clutch ECMV: Short circuit
Ptl
E03
DXH6KA
3rd clutch ECMV: Disoonnection
PIT
E03
DXH6KB
3rd clutch ECMV: Short circuit
PN
E03
DXH6KY
3rd clutch ECMV: Short cirorit
PN
R clutch ECIl|!V: Discon neclion
Electrical system Elecbical system Elechical
sy$em
DXH4KY
DXHTKA
sy$em
Eleclrical
E03
E03
sy$em
syslem
syslem
Ptl
Electrical
system
E03
DXHTKB
R clutch ECtvtV: Shod circuit
Pfi
E04
DXHTKY
R clutch ECMV: Short circuit
Ptl
Electrical
Ptl
Electrical system Electrical
DXHSKA
F
E03
DXHSKB
F clutch ECMV: Short circuit
clutch ECMV: Disconnection
Ptt
E04
DXHSKY
F clutch ECMV: Short circuit
Ptl
E03
DXH9KA
Right clutch ECMV: Disconnection
Ptf
6
Part 4
Electrical sysrem Electrical
Electrical
E03
Part 3 sEN03208-01
Electrical
E03
E04
by failure code,
system system
syslem Electrical sysrem Electrical
system
D15546
40 Troubleshooting
Action code
Failure code
E03
DXHgKE
Righl clutch ECMV: Short circuit
PT
E04
DXHSKY
Riqht ciutch ECMV: Hot short
Prf
E03
DXHAKA
Left clutch ECI\4V: Disconnection
P/T
E03
DXHAKB
Left clulch ECMV: Short circuit
PlT
Trouble (Displayed on screen)
Component Category of In charge history
E04
DXHAKY
Left clutch ECMV: Hot short
Pfi
E04
DXHBKA
Rioht brake ECMV: Disconnection
P/T
E04
DXHBKB
Right brake ECMV: Short circuit
Pfi
E04
DXHBKY
Right brake ECMV: Short circuit
Pfi
E04
DXHCKA
Left brake ECMV; Disconnection
Ptf
E04
DXHCKB
Left brake ECMV: Short circuil
Prf
E04
DXHCKY
Lefr brake ECMV: Short circuit
Ptf
E03
DXJ4KA
Weq lock Sol-: Disconneclion
PN
ED3
DXJ4KB
Weq lock Sol.: Short circuit
PN
Reference manual
Electrical system Electrical sysrem Electrical system Electrical sysre m
Electrical system Electrical system Electric€l system Electrical system
Troublesho.rtino by failure code, Part 4
sEN03209-00
system system Electrical system Electrical Electrical
system
Entry order of items in table The items are entered in the order oftheir failure codes (incremental order). Action code Attached: lf the failure code is detected, the action code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. Pn: The Dower train controller is in charae of detection of fault. Category of record Mechanical equipment system: Fault information is recorded in the "Mechanical Systems". Electrical equipment system: Fault information is recorded in the "Electdcal Systems".
D155A{
7
40 Troubleshooting
Fuse locations Connection table of circuit breakers and fuse boxes * This connection table shows the devices to which each power supply of the fuse box supplies power (An accessorypowersupp|ytsadevicewhichSupp|iespowerwhi|ethestartingswitchisintheoNposition i" a device which supp|ies power whi|e the Starting switch is in the oFF and an unswitcheo po*", "uppty and ON positions). * When carrying oui troubleshooting related to the electrical system, you should check the circuit breakers and fuses to see if the power is supplied normally' Circuit breakers CB1
-
CBg
Circuit Po{rer circuit breaker (TypG of pol{er suPPlY} breaker No.
Circuit
cB9
204
cBl
20A
c8105 supply)
a
Emergency pov/er supply (For power lrain switch bo4
Work equipment contloller
eIn Air conditioner unit, blower motor, and compressor electromag-
c83
netic clutch
cB4
20A
Headlamp, additional headlamp
c85
20A
Rear lamD, additional rear lamp, ripper point lamp
c86
20A
cB30 (Unswitched power supply)
Optional power suPPlY Power train controller
20A
(Accessory Power
Destination of Power
breaker capacity
Sarting switch Engine hold relay Machine monitor
cB7
20A
Power train controller
W"tk cB8
30A
cB105H
"q,r',pt""t
"""tt"ll*
Engine controller, Elecuic priming pump Engine elec{rical intake air heater
(Unswitched power
supply)
Fuse box FS1 Power circuit breaker Oype of power suPPlY)
Fuse No.
cB30
Fuel
capacity
204
(Unswitched power
Ilestination of Power Operato/s c€b power supply (To connection table of fuse box II )
supply)
c8105
5A
Backup alarm, backup alarm relay
(Accessory power supply)
3
20A
4
204
Operato/s cab power supply (To @nnection table of fuse box II ) Operato/s cab power supply (To connection table of fuse box tr )
Starting switch (ACC)
5
5A
Engine controller (Signal AcC)
I
40 Troubleshooting
O
sEN03204-02
FuseboxFs2 Porvor circuit br€akel (Iype ot povU€r supdy)
Fus€ No.
Fu€l
Destlnadon of
capaclty
powr
cB30 (Unswitched power
'I
5A
Pedal brake solenoid valve
5A
Parking brake solenoid valve
supply) Engine electrical intake air heater
c8105 (Accessory power
20A.
supply)
Pneumatic susoension seat
4 S-tading switch (ACC)
Dl55A$
Ripper pin puller solenoid valve
5A 20A
Hom Optional power supply
I
40 Troubleshooting
sEN03204-02
Localions of circuit breakers C830, C8105, and CBl05H (ln battery room)
Locations of circuit breakers GBI
(1) (2)
-
GB9 and fuse boxes FSI and FS2 (ln battery room)
(3)
(4)
(5)
o
(5) (4) (3)
(2) (1)
o oooooo | ,l. l' .\ ir. . ..
10
D155AS
sEN03204-02
Fuse box
I
Power circuit fuse (Iype ot power supply)
Destination of power
FS l-1
(Unswitched power suPply)
10A
12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)
Additional light relay, additional light FS1-3 (Accessory power suppry)
12V accessory connector (Via DC converter) 12V accessory socket (Via DC converter)
Windshield wiper (Via intermittent relay) Front wipet rear wiper
Location offuse box
II
(ln operatofs cabl
c I
\o
' r--ir'\ t==a\ o -
\
\2-===
""--;)
D15544
11
D15544 Bulldozel Form No. SEN03204-02
O 2OO9 KOMATSU
All Rights Reserved Printed in Japan 06-09
12
KOnA|'1SU
sEN03205{2
SIIOPMAN|JAI-
BULLDOZER D155A-6
) Machine model
Serial number 85001 and uP
Dl55A-6
+o-rrouuteshooting
ttoubl""hooting General information on
xonri'lsu
D155A-6
40 Troubleshooting
sEN03205-02
Sequence of events in troubleshooting Office, shop
Nr^ \-(
2)Ask questions to gain an outline of the problem. ' Condition offailure
. Work being c€r.ied out al lhe time ot the tuilure . Operaling environment . Past hislory dgtails of maintenance, elc.
Step 2 Determining probable location of cau6e
possibls causes.
'l
nl:(;a
) Look ai the table of troubleshooting tools in the shop manual and prepar€ I the ne€essary tools. . T-adaDter . Hydraulic pressure gauge kit, etc. wrat2 2) Look in the parts book and prepar€ the necessary replacement parts.
lRt
iffil I *
lFl tFi .e
& ry
TE$00 t 86
lil
-ft^
LUI
n^
(cany out troubleshooting) . Decide action to take ) Belore starling houbleshooting, loc€te and repair simple failures. . Check before $tarting items . Other check items 2) See lhe Troubleshooting Section the shop manual, select a
\
1
nfooJ
rtl"%qo of
'@{ E&
boubleshooting flowchartthat matcfies
I I Re+nAtinglai=itur€l Drive and opor"te the machine to confim I . thEucondition and judge if there is really a L
I
I I
Step 5 Ask operator questions to details of failure.
3
sEN03205-02
/O Troubleshooting
Points to remember when troubleshooting A :::tj.: y"hine in a revet sround, and e,.,u^ check rnar thar rne the tock I pin, btocks, .,rq and Partong parking Drake brake ar€ are n irljfll_Tld . a when the oorerarion a..^ _, ^_ "lrv,ng "rt 'i'r
";lli:"1T,1ni;T1#*lt|ft1iii-T$il;#"'='keepstrictrvtotheasreedsisna,s, .'oubleshootins' :iii',i;f ilH{:iil1-E?trlll?l;Ti.:::l?ntr"vspurtourandcause +3:ffi n"t o"tt- o, iJ's"';g disconnec{ins "Tfr w,nno'::].:l "nY. ? .:.nen awhenremovins*"o,ni';lll?1i1'"*{x;i''.#fiif:iii'.,:iii:.,-3,.iil"nf""ffoo^, ;:Tt,,',".f#he inieriar pressure R.st. wi;;';#;d;::ilflr"il,,,t;"#,:il:'*.f*: The aim of troubleshootino is to
p
point the basic cause of the fa or-.ne railure' to carrv out repairs swiftlv, and to prepoint H-owever' *io't 'lp"Fnt i. i" is or cour to understand the structure and function. or possrbre" causes o, the fairur" ,l:ollg:lo*'ng ouestions to form some idea hat wourd "rij;," ;se v.enr reo@urrence of the failure.
I
yynen carrying out troubresnoorno
; ,::--::-u::
*ito-""nili'"'9:ill
p'"0i,""1i",ip"i;',iXffi;;';"^
t
out Y.Tl^toTrrytng disassembre
Il,nurry components any fairure
r
do not 4l -r components. ' are oisassemf,t"i-,,,i--r,^.^,.. - -*---"tbled immediately -. troubtesnooting,
the
5)
oaar.,,
P-arb that have no connection with the ure other unnecessary
parts will be
-or assembled_
faitdis- 4.
-check spool.
the stroke of the contror
varve
other maintenan@ items c€n be checked * itemin", ," *n:,1t:"j:-.|.|r. sldered to be "rrecr "nv
ntc""""ry.
Confirming
failure ' llfi||f;rT: impossibte to find rhe cause . :El.g_.; :xrenr or the raiture yourserr, rtwirarso""u"J ormanhours,.parr" "*".t" grease, and ,fJ,ffff:l filii:::Jfi,fftHl?ff at the same ttme, will also operar|on, l:'1.-or etc. rose the contidence of the user or
iffi,ii?"'13;J*:l::'g'"t
prior
investigatio;;il;
;l:.",,nn
2.
operator. out
proce_
t,
a
l:;,flfl5lp[u"i," rre pmorem'tnai h;#; ,, ll,'_T fiffii# 4, Was there envrhi-^ siraiil'about ^.-^--
occurred aparr
3::,1"1.""t*ins the fiiture
U)
ri""tl,iil
the
a
yl"1,r"r"
ffi:.:?'
;j ;flli;fiJi:#ff:,,ff
out before
these repairs canied
out?
The basic procedure for troubleshoot_ ing is as follows. ll"1 1", the simpre points.
ll
what conditions did the faiture
the failure?
t^,
*
witr tne maliinl conoition
a.ny repairs been canied Lt"o.
of rhe investisation and *:^,11:*fo o-"^t:l'".,rr. t : ; i"""il;'il;;
lf thecalses of faitu., *"" ,"" rowchgrttorocaiJiie"posrtionor :lo:li:.'9-f the failure exacfly.
occurreoz ., uld 3?"Lin" lgjore o, the faih|'a o"",r ^..,, .,ol#ry, ^^^,o.,"r.u fl:11*^flg
^r:-Oul occu|?
;",":X;?*,".,i1:;*:ru:l]:1,il
prootem worse. Troubleshooting
5.
Points to ask user or operator
O)
when operating the machine ro reen_ troubres-rro*ins:;i,o,", oo
act ttre
Hfr:X1T:',T,r":
in accordance with the fixed
;T,::jf!,^"r. before this?
*
troubre-
,J
information. 6.
same kind or rairure ol"rrr"o
rroubteshootins 9,n"to"t:l: uneck the oil level for any external reaxage .Check of oil from ,.ls nydrauric equipment. 9, q uneck the travel of the control levers_
r/ 2)
", Ifj'f
.f
ea113_s .t-o
ff [J:,
qemgv€ roor cause of faiture
is repaireo, it tne root L:l ifofthethetuiture cause failure is not
repaired, Ine same failure will occur again. a *a ys"ir ves tigate wny
P" *."",f::.1,:, o"",'.'."01 ir, j5.ryt' root cause. r
"nli";:;"t
J
2 D155A-6
/O Troubleshooting
sEN03205{12
Check before troubleshooting Item
Lubricating
oil/Coolant
Hydraulic/ Mechanical equrpmenr
Remedy
Criterion
1. Check of level and type of fuel
Add fuel
2. Check of fuel for foreign matter
Clean and drain
HH-
3. Check of hydraulic oil level
Between H
L
Add oil
4. Check of damper case oil level
Between
L
Add oil
5. Check of oower train oil level
Between
L
Add oil
6, Check of level and type of engine oil (in oil pan)
Between H
L
Add oil
-
7. Check of coolant level (in sub tank)
Between FULL - LOW
Add coolant
8. Check of dust indicator for clogging
Oui of red range
Clean or replace
9. Check of brake pedal stroke
Adjust
'1.
Repair
Check for abnormal noise/smell
Repair
2. Check for oil leakage
Bleed air
3. Bleeding air 1. Check of battery terminals and wiring for loose.
Retighten or replace
ness and oorros|on 2. Check of altemator terminals and wiring for looseness and corrosion
Retighten or replace
3. Check of starting motor lerminals and wiring for looseness and mrrosion
Retighten or replace
4. Check of battery voltage (with engine stopped) 5. Check of electrolvte level Electrical
equipment
20-30v Between H -
Charge or replace L
6. Check of wires for discoloration, bum, and removal of cover
Repair or replace Repair
7. Check for released wire clamp and drooping wire
L
Check of wires for wetness (Check conneclors and terminals for wetness, in particular)
Dry
9. Check circuit breaker for turning oFF and fuse for dismnneclion and oorrosion 10. Check of altemator voftage (while engine speed is at middle or higher)
operating sound (when starting switch is turned oN or OFF)
11. Check of battery relay for
4
Add or replace
Replace Affer operating for several minutes: 27.5 - 29.5 V
Replace Replace
D1554-6
40 Troubleshooting
sEN03205{2
Classification and procedures for troubleshooting Classifi cation for troubleshooting Type
Display ot code
ContenG Troubleshooting by failure oode
E mode
Troubleshooling for eleclrical system
H mode
Troubleshooting for hydraulic and mechanical system
S mode
Troubleshootin g for engine
Procedure for troubleshooting lf a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section.
o
1.
Procedure tor troubleshooting to be taken when action code and failure code are displayed on machine monitor: lf a action code and a failure mde are displayed on the machine monilor, cany out the troubleshooting for lhe conesponding "Display ot code" according to the displayed failure code.
2.
When eleclrical syslem failule code or mechanical system failure code is recorded in fault his-
tory: lf a action code and a failure code are not displayed on the machine monitor, check for a mechanical system failure code and an electrical system failure code with the fault history function of the machine moniiorlf a failure code is recorded, carry oul lroubleshooting for the correspondang "Display of code" according to that code. ll an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is still detected. A failure code of the mechanical system cannot be deleted. lfa trouble is displayed in the air conditioner fault history or heater fault history by the fault history funclion, carry out lhe corresponding lroubleshooting in "E mode".
* * *
3.
When action code or failure code is not displayed and no failure code is recorded in fault
history: lf a action code or a failure code is not displayed on the machine monitor and no failure code is recorded in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In lhis case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
D155A6
5
40 Troubleshooting
sEN03205-02
Information in troubleshooting table
*
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Belore carrying out troubleshooting, understand that information fully. Failure mde
Action code
Display on Display on machine machine moni-
trouble
Trouble name dlsplayed in fault hislory of machine nronitor
monitor
tor Contents of
Trouble
Contents of trouble detected by machine monlior or controller
Action of Action taken by machine monitor or controller to protect system or devices ft'hen they detect machine monitrouble tor or @ntroller Problem that appears on machine
Problem lhat appeaB on machine as result of action taken by machine monitor or controller (ehown above)
Related information
lntormation r€lated to detected trouble or troubleshooting
Standard value in normal statsrRemarks on troubleshooting
Gause
Standard value in normal state tojudge possible causes Remarks on judgment
. . 1
DBconnec{ion Connector ls connected deteclively or wiring hamess ls broken. . Ground tauli wiring harness which is not connected to chassis ground circult is in contact with chassis ground circuit.
.
Possiblecauses
Hot short
.
Wiring harn€ss which is not connected io power source V) circuit is in contaci wilh power source (2/t V) circuit. Short circuii Independent wiring harn€ssss ars in contact with oach other abnormally.
Possible causes of trouble (Given numbers are refer ence numbers. which do not (1) Meihod of indicating connector No. and handling indicate priority)
and standard Yalue in normal SIAIE
3
4
8
.
(2,1
ofT.
adapter Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specifisd. . lf connector llo. has no marks of "male' and 'temale", disconnect connector and insert T-adapters in both male side and female side. . lf connec{or No. has marks of "male' and 'female", di8conneci connector and conngct T-adapter to only male side or female side. (2) Entry order of pin Nos. and handling of testcr leads Connect positive (+) lead and negative (-) lead ot t6ter as explained below for troubleshooting, unless oth67wis€ specltlad. . Connect positive {+) lead to pin No. or wiring hamess entarod on front side. . Connect negative (-) lead lo pin No. or harness sntered on rear side.
D155A-6
40 Troubleshootlng
Relafred
sEN03205.02
circult dlagram
This drawing is a part of the electdc circuit diagram related to ljoubleshooting. Connector No.: Indicates (Model- Number of pins) and
. . .
(Color). "Conneotor No. and pin No.' tom each brandring/merging point Sho!$ ttre ends of branch or source of merging within th€ parb of the same wiring hamoss, Afrow ((-)): Roughly sho^'s the localion on the machine-
40 Troubleshooting
SIP trDe coineclof prns lia
le {i
ema
le
hous
insl
Fena
le
(na
13t
lE housinsl
t I
t6
II
t3 8flP04 7|
Par
I
t
BlvP01716
5
:08055-ll68l
l{0.
PDrl r'lo. , 08055-1 l6S1
'Electric r rre size:0.85
Terninal Dart No. : 'Electr ic iire sire:0.85
'Gron|llel:8lac*
'0r onnet
'0'tv:
'0'ty:
Te
rninr
oart
No.
r
20
T!rmrnal Dart No.:
:B I d ck
C
20
Termrnal Dari No.
:
'Electr ic rire sizer 1.25
'Electfrc Nrre size: l,
'Cronmei:Red
'Gr onmet :Red
'0'
ty:
20
ts9-601-7320 lT-3dar I e r)
?5
'0' t y: 20 B4D|8r92
o
o 12
D1554-6
sEN03205-02
ll type l,la Pa
rt
le (1ena r,1o
le
connectcr
hous inoi
Fena
:08058-00171
(na r
Part No.: I
I
I: Iryii
e
9r,
hoLrs in sJ
tfrc ar i0rl
tg9-601-708c (T-rda rt er)
C8055 00181
2
\:ffi. /n1t\ ilTi! IL4aJI
- --lItt s ?{.-I= dt-1 \e2 , I
lwh l'-Ell
TI
awpo+r
Part No :08056
le
r
r
I
(r-adaDter)
El{P041I
I
00211
i 9!-60 t-7090
Par
I
I
No. : 08056 00281
ffii W
BfPD4 Pa,
r
i
r,0
?s9-501-l]IN lT_aCr.ler)
l
8vP04
fio. : 04056 00311
7
20
ho. : 08055 00381
r99-50 t-l;2c (T-dCaoler) 1
8|{P04721
Pari
1,1r.
: 08056-04111
esP04 72
Parl
No. : i8C56-00a6
2
|
.lFnm -+ m + t--#= Eft '/-\3
oart lic.
: 08056-30611
Pert
7S9-60r-1130 (T-adap t e rJ
*on'rn No.
: 08056
00681
7S
g-6C I
lT-ad
Pa-
t No.
-.8056-00871
Parl
-
a o
134C
ier)
tlD. : 08056-00881
B4Dr8r33
lr I
Dl55A{
13
40 Troubleshooting
S trDe connector
of
No.
Na
ie Iteoa
le
fema
hoLrsino)
le (nale hous
rn
t0!
e)
I
?sg-60r-7t40 lT-Ndaqter)
I BXP0472
Br{P04 } 2?
Pari
Part
ND. ,08056-108?1
No. : 08056
0
1C801
10 (t/h it el
7S9-60r-7t5C
{T-sdaoter)
t0 8\vP01730
BWP0472g
Part
No. r08056-11011
08056 I I081
12
?s9-601-7350
0h ite)
iT-adaDle.)
lt
BrP04I t2
8vP0rl3l
Part tlo, : 08056-ll27l
Part
No.
:
08056-11281
16 (Ylh
799 60 r-7330 lT_adapter)
itel 1[ 8wP01733
Parl
No, :08056-116?l
Part tlo. : 08056-l l68l
8{0'81s4
14
Dt
55A6
10
S tvoc cannector
alcilenare rrusr'rel
I
Fena,e:rale loLs tgl
t:
l8
ue)
4l 1t
nt -i
12
(Blu3j
:t
\ffi'"
I
tr€aii
I
[
8lt
I
|]@QJl
I
fl6clr
7S9-6C:-?r60 {T-ad apI
,lE9l*-,', I Ho. r 08056- l
8rPt.
B[P04 737
rl
118
;rrt Ni : 08056 I1232
l2l2
'..\ffirt'
I
e
llEEl
1,ffi
1E
Itrdl
i8, re)
ItDDI
t0
BtPt4l3g
6,,#h'.t
I=_EN
l-==-v
t=v
7S9-60 r-1170
(T adaDter)
BtP04I4
0
a D155A{
15
40 Troubleshooting
sEN03205-02
l.l
a
le
[lellale
| 794-222-2614 i0' i v:5)
Eody
rari
Eodv
part ilo.
Fenare ina
ho,Jrirs)
No.
: 79A-222 2680
Eody
Bod
!a"t
ND.
le
hc
u
s
in.l
: 7SA-222-2630
y port Ni.:7SA
222-2670
(0' tv r5)
3--'FFF-'--I r---€JBI$.-..-1 i 2l rC (I-3daDtef)
7S9-60
Eody
part
l{0. : 194-222-262C (0' t v:5)
Ecdv Dert
llo.: iSA
22?-2610
(0' t v:5)
--,F-u-E-ef-
r-ll
ril nfi Sodv
oarl
7
No. :7SA-222-2660
t0'
S
!-60 r-2S50
(r_adapter)
No.: l3A-222-2650 (0' t r,5)
t v :51
t---.|6;;n515;Q--/'
r:._&u4r
i99-60 r -2120 lT_rd, p I e')
o.:734 la'ryt2)
?22 2710
Eodr oarl No :7SA-222-25S0 (0' tv:2)
g4Dt8tg6
16
D155A-6
,r*r,o*a l
40 Troubleshooting
NIC troe corIector
T
lt ?9S-601-2t30 lI-od aoi er)
8lfp04t4I
8tfPc171l Eody
oart
No.
:19A 222-2134
SoCy
eaft
Hc. :734-222-2121
i0'
B\YP0
Body .ar
I
r,lo.
:
79A-22t-2750
Ie:ninal part \0. : lgA-222-2170 (C'tv:50)
t)15546
4l4
tv,2l
S
v part l{0.:7EA-222-27,ri i0'lv:2) part Ie'rixa I lio.: i3A-222-27€0 Boo
(0'
t v :501
17
40 Troubleshooting
sEN03205{2
No.
AllP0.+0 l vpe connector
of l,la
le {fe|!a 1e houslnoi
Fema
le
(na
le
s!er
ho!srnsl
|
ii
[ool
|
?9S-60 7t 80 (T-ad a oi erl
I 5
B|dF017 52
Hou s
/ns Darl fi0.:7SA-222-3430 (0' tv:5)
799-60 r-7 t 90
t2
(T-adsoter)
1
BtPC4I51
BWP04l53
Hous
ine parl
No.
:l9A-222-3440
(0' r v:5)
79S-60t-72t0
l6
(T-adaDterl
s
8;P04I5
8WP0r7 56
5
Housinc aari No. | ?9A-222 3450 (0' i r
,51
l9 s-
20
60 |
-ir20
(T adaDlerl
tl 8rP01? 57
Housins par
t
No.
:79A-222-3460
(0' t r r5)
84Dr8tS8
18
D155A-6
40 Troubleshooting
sEN03205-02
Na
le Itemale
hoLrs in s)
tr-
'-:m IIIH =.l Ll.lE5 :=J ,o# =J
jil :r
I
L9l
l+''-ryu I dr I tirF I
o
I
I lr-_J
#,,FK'0n.,0,,.u
rl
I
I
I
Part o. 132l-S2 7330 lo
ffi {
\
|
|
f,l +I
I I
=
6\
)4/-
ffi,t 'Lll.:lL
r1
'iE6ffi
I :J,l I t:= fg "t rrllt hlllrsl,
r']F td- *JF
I
lf:ll=lF
T+- -#Hl . - lZ !
pyplq z6;
'r-o
,,H,* Par
I
l
-6i r-1510
(T-adaD t
e
rl
No. :7821-91 ?340
ii-t!
t::=
t-d l=-rn-= r[
h---lF
l1
arp nr I
s:
739-60 r-7530
(;-ada ct e:l
i-t>l
BYIP
Parr fio.:1821 g!-13r0
JLt'ffi, = |
o
tt:|t4tr
4
|
[;]t!F
HFS
l8srpo+ros
-lEI-'#
F_
I
-- _l 20 s',vpo+ror
D1554-6
llHi*Ul =]C I tri+fDli r-E I I;IFEF'I _Il@rLs =li
=s
19
tO Troubleshooting
sEN03205-02
0i
I
oressu
r€ seisor
0t
Srnsor
side blu!)
w /-1"\ ,r,7t-l\,\ ///ffiI\
lrPtR
fro.
piltns
l,!s
le Din lleqiale
housins)
! rl ldrl
tlsrIess side {rec€ptrc lel
79S-601-S,420 {k
ir :79t-601
ii,
-4 t0 tl t :199-60r -120 r1
iI{TERI riTEl{T lrll l1 Fens
ie oin
{male hou3ino)
tl
Dl820C
20
Dl554-6
40 Troubleshooting
sEN03205-{r2
l\ lE IHF d--.---__l r.____1 | IffiiLl
_'9
l---!Jt F._
I
-lT
r-l
IUJ
tsfP04l rc
o _\I |
|
*lalfil;r# l\ t-! Jll FrsEE+ ffi
riffiffi
r--
,f-t
8tP047?g
Fart Io. ; 08027 10410 (Nstura
Part
I
No.
|
08027 10420 IB ack)
72
BrP0
4
i3C
o
08027-10160 [Naiural col0') 08027-1017C {8leck)
E
i--] Parl No.:08027-10610 {ll.t0ral coior) 18C27- 0620
(glaLkl
i |
Prrt
No
:
08027-1t660 lNai!ral color)
0802?-10670 (8lac!J
84018r02
22
KESI lAut ofioh i
l,rsle{fena e
lousinol
|
lel
cc nn
ecl
oi
.emale(ndle hous qr)
D._ lr Llt lr--------r -EJ I
| |
-.1
|
8vP 0,i 7s3
No. :0802
Pa't l\0. :08027-
7 10010ltl.tufal
0e02? 10820 (;lackl
10960 ([a t !
ra
0802i- 10870 lErrck)
ilele(feno e l.ousins)
|
Eenalehale hrus nrj
,q
fr- bFA -F ,,-r# '"o"r{r -fr
--_
t
7S! E0r 1350 LI-adarte,)
ii
u-.\J.jo
rrr---
i.
FP\,
l'
3
erpo, 18"
BW;04786
6r
--a ,3 rffifrt -til uUt
3
aal
.84s,
I
I
Bvl
P01t
ql
ll-
JlilL!
| /^1
I
ll lL-/l
11, ,,--J
79S-60 t-1370
{--adapter)
8l
I D1554{
23
iO TroubleEhooting
sEN03205.02
Connector
No. of
,ins
Fene le
(lera
le
for r€idv (Sorlrt
housi4e)
lvDel Re
lar (ra1a housio.)
l{
\li I
bfril' rffi^ r -Hil-:'' F{"
5
Paf t d0. :7861
Par t No.:7861-74-5300
74 5r 00
F
No. of 14a e {l efia
le
hous
Fefla le (na
insl
le
houi
in.l
,---r-l
r--______a
I BYiP03905
g4D | 0101
24
D155A{
40 Troubleshooting
sEN03205-t 2
:0r
I
e
c'o
r
:
a
.
s
c
:'
I
c arre irsefr irn
en0
size
I
Pi.lraale terrinalJ
S3cket llemale tErminat)
l9l
501 -3 2
lT adaoler)
No.
:08lgl-1 201.05lgl
118'gi-t t205i 081-01
18-5
Nc. :ngl91
1r202,
|
206
081
9
t0
-l1l3l, 0gl9l-l!102,
r- 14105,
08
r3
i{106
(ll
7S9-60r -S2 rD
lT-ldaote:)
Pii
{n?
le te.n,nal;
Part
No. r08r 031
Soclel ll
ema
le
gr-2!r0r, 08lst-2.4102, 3r-24r05, 03 3i -i1:06
termlnal)
/.----;\\ /,/d o."\'
i
I
D155A-6
o"
-,
i
or,oro ^o" , oF\ \ O' sB O-/
ho. :c619
|
2?20l, :8 | I
79S-60 i-S220
i-T-acapterJ
| ttot, ??20[
0srgr ?t?05.0619t
?
i
I
Paf
t',10. :081 9l-23101, 0819'-23'02,
cSrsr 23r05, c8r9r
23 r06
25
lThe
lsne
oii
No.
ls also r$arked on the
HD30
tl P
ir
(nn
Le i
e
rri lna
l{ire inseition erd)l
Series conneclor Bodv (recep t ac
dr (olrci
8o
coCel
c0nneclor (eLeclIic
l,
!a
lel
(ter,le ternin.
Socket
l)
ie os .ii ']lo .l .I tll\
799-60t-s230 (T-aoaoler)
(':.1.:l.z BrP0 50 r0
Pari
No. :08191-31201, 08191-31202
Part \o. :c8l9l-31101. Prn (na
,A\ /(";'l;lr:,l\\ t
No.
Pari
ter[linal)
:0
8|S|- 33I0
ena
1
. 0I ! 1
I-
3
3
1 0
te
r)
2
le
//,.tr-_-;..\ 7'"1 "r''g\' /,ro o o.on6tt1 roro''\
7!9-601 (r-adEp
[..o o3o o ol?/ vo
| ,.r.'11 t'' 1ll /
\1i)/
18-r
No.
Socket tl
.6
\"o
(r-adap
\i!tz
,/,2----:r\ ...
7S9'6C I -9230
I
\oll .,.1 .: ,3ll/
7j!.,'iN /ro. . rar."\ |
o
//.rr .z .r rlo\\ l.''.r rr .a or'l
/
:08191-32201,08r9r 32202
Pin (male
le ternial)
/z -z--;-'\ \ / /,..r0.! 08\\
\s.!/
Par
08191-31102
S24C t e rl
\"dj,,
Par1 No.:08rgl 4l2al.08l9l 12202
Pa.t
o
No. :08191 44101, C8l9l-41102
1
(1'
Socket
Lf
Pin
enale telmrnal)
(,na
le ter
ra
ll
,'ffi\ ' Part
('r.
""d;;':'i \i, #/
No.
739-60 r-9240
tT-addpter)
' BtP0 50 t6
Bwpo.or5
:08lgl-r2201, 08lSl-42202
Part
No. :08191-,+3101, 08191-43102
B40rB4C6
26
40
Troubl€shooting
sEN03205-02
na r
Ie0
cn
(shell s i1e
!od y (o
I
rs)
Bod:l lreceD t aD le)
7SS-601 -S230
iT adaDterl
tsv/P050 r 7
-QYlP050 r S
08 t91 -511 Cr, 0019
SockeI liena
le iernirarl
Pin {na,
/t---;r\\
/ ci o'\
Prrl No. 08l9l-53101. Socket
/A.
21- 16 i6i
// ot o^ oE o1\ \ ' Io"or ,oo6c1 ' \\ orooo..or/ /
|
g1-61201, 08191-62202, c8t st -6t205, 0819t-6220t ena
ie 1e.n
\---j,'
Bxlpo 502 I
{c. :08i
Sockel lf
Part \o.
nall
!
r
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27
40 Troubleshooting
sEN03205.02
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28
D15546
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Troubleshooting
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No, :081 gl-94103, 08lSl-94101, 08|9t-!4 r05. 08 | 91-94106
le tErniial)
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799-E0r-9290 (T-a
Btrp0 5035
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No.
:081S1-92!0:, 08191-32204. 08r gr -92205, 08r9r-92206
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gl-93103, 08lgl-93101. 08t9t-s3t05, 08tgr-93t06
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810
S
40 Troubleshooting
sEN03205.02
IThe oin No. is also ||rrked oo ihe conneclor{eieclric
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r]re insertlor
end)l
DJ Ser e9 connector
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7S9
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2
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790-601-9890 tI-adaD t e r) 8ytp0 5038
8fp0 5037
Part
No. :08192-12200 [normal lvpe] 08192-22200 (f ine ii te tvoe)
Pari
No. :0glg2-12100 0 0 | g
2
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0
0
(normal tvDe) ( t i i e lr i r e t,
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